Plastic floor coverings



June 8, 1954 R. F. scHNEE 2,680,693

PLASTIC FLOOR 'COVE-RINGS Filed Dec. 3. 1949 7 Ullar Mlm' y. 35 INVENToR.

oaERT- Ff Scl/NEE BY Patented June 8, 17954 y UNITED STATES PATENT OFFICE PLASTIC FLOOR CGVERINGS Robert Francis Schnee, Barberton, Ohio Application December 3, 1949, Serial No. 130,953 2 claims. (o1. 154-49) This invention relates to plastic floor coverings, and particularly floor coverings for use on aisles, hallways, and other long, narrow floor areas in office buildings, etc. The door coverings are made up of a plurality of individual mats. The invention includes the individual mats as well as the floor coverings made from them.

At least one edge of each mat is formed with projecting lobes and recesses between them, and the lobes of each mat are interlocked in the recesses of an adjacent mat. Mats which forni the end or side of one of the oor coverings of this invention may have lobes along only one edge, and the other mats will have lobes along two or more edges. This permits a number of mats to be interlocked end to end to form a runner of floor covering of any desired length, with suitable end and side pieces as required. By using mats which are not rectangular and mats with lobes on more than two edges, floor coverings of a variety of shapes may be assembled.

The shape of the lobes is complementary to the shape of the recesses. When interlocked the mats resist being pulled apart. The lobes and recesses are preferably designed to resist vertical dislodgement by providing interiitting male and female irregularities in their walls. Some or all of the lobes may be thinner than the adjacent mat material, with their tops on the same level as this adjacent material. The recesses designed to cooperate with the thin lobes are provided with Webs which underlie the lobes, and the total thickness of the lobes and webs is equal to the thickness of the adjoining material. Ordinarily web-free recesses will be preferred with lobes the thickness of the adjacent material. However, mats composed of a relatively soft plastic are advantageously provided with at least several thin lobes and webbed recesses and means for fastening them together to prevent separation of the individual mats. These assemblies are advantageously located at or near the ends of each interlocking series of lobes and recesses, and if the mats are wide one or more intermediate lobes and webs may be fastened together. This prevents the lobes from being dislodged if the mats are twisted or flexed at the interlocked edges. If the mats are formed of a firm plastic, such fastening means are not required and all of the lobes and recesses are generally of the same thickness. Even though no fastening means is used, and regardless of whether the mat be soft or firm, a web may be provided under all the lobes to prevent dirt and dust penetrating between the interlocked edges of the mats. Such webs may underlie all or only a part of each lobe.

The mats which are assembled to form straight runners of oor covering are of rectangular shape, and generally will be of the same width. Sectorshaped mats are used for turning the floor covering around a corner or an obstruction. Mats used at intersections may be of any shape and may be formed with interlocking members on any number of sides depending on the number` of intersecting strips to be fastened to it. Short mats with lobes along only one edge are used to form finished ends for the runners, and for sides as well as ends on mats having lobes on their four edges.

The series of lobes and recesses on all mats of the same composition and width are to be standardized so that they may be assembled in any desired pattern. Mats of the same shape will be interchangeable and a worn mat in any assembly may be replaced by a new mat without replacing the entire assembly. All mats in any assembly may be of the same color; mats of different colors may be used to form interesting designs. The mats in any one assembly will generally be of the same composition but mats of different composition may be used, employing more abrasion-resistant compositions where there is the most wear, etc. Rubber, synthetic rubbers, vinyl compounds and other resilient plastic may be used in forming the mats.

The under surface of the central portion of each mat is preferably grooved, and the under surface of each lobe which is designed to engage a Web-free recess is preferably countersunk in some manner to give added resiliency to the floor covering. The upper surface of the mat may likewise be grooved in which case the body of the central portion of each mat may be corrugated in cross section (Fig. 8). Such grooving, etc. results in an appreciable saving in the amount of plastic required.

The invention will be morefully described with reference to the drawing, in which- Fig. 1 is a plan view of several interlocked mats of different designs;

Fig. 2 is a plan View of several interlocked sector-shaped mats;

Fig. 3 is an enlarged fragmentary view of a corner and several end lobes of each of two mats which are in a position to be interlocked with each other;

Figs. 4 to 9 are cross-sectional views, each being taken on the section line of Fig. 3 correspending to the number of that figure;

Fig. 10 is a view of the mat portions shown in Fig. 3 after they are interlocked; and

Fig. 11 is a cross-sectional view taken on the line lI-ll of Fig. l0.

Runner mats l are generally rectangular in shape, as shown in Fig. 1. The lobes 2 and 3 which project from the ends 5 and 6 respectively of each mat (Fig. 3) are interlocked. The portions 8 of the mats in which the lobes are formed are of uniform thickness, being about one-fourth to three-eighths inch thick. The outermost portion of each side 9 of each runner mat l is beveled from this thickness to a sharp edge l as best shown in Fig. 9. This prevents the mat from curling along the sides. The under surfaces I 2 of the sides il are flat, The interior or body portion of each runner is corrugated at Ill so that as the mat lies flat a cushion of air is entrapped under it. rl`his makes the mat a more comfortable surface to walk on than if the mat were solid. The eorrugations blend into the top and bottoni surfaces of the thick portion il at each end of the mat.

The contour of the lobes 2 and lobes 3 is similar in that the outermost portion 2! of each lobe is a circular are and each is attached to the mat by a narrow neck 2i. Between each two lobes there is a recess 23 the saine shape as the lobes e so that the lobes and recesses of adjoining mats mesh with one another. In the preferred form of the invention the vertical walls of the lobes and recesses are provided with the interlocking male and female irregularities. All the lobes i at the y end 5 of each runner mat l are female, and all lobes 3 at the end 6 of such mat are male. The lobes on the end mats 2t are female. The lobes on two sides of the mat 25 where the runner rnats intersect, are female, and the lobes on the other two sides are male. The recesses opposite lobes 2 have male congurations on their vertical walls and the recesses opposite lobes E have female configurations on their vertical walls. Figures 3 and clearly show how in interlocking the mats the ends 5 which are provided with female recesses and lobes readily intermesh with the ends 6 which are provided with male recesses and lobes 3. when the two sets of lobes are interrneshed it is apparent that they cannot be pulled apart longitudinally because the lobes are wider than the openings to the recesses 23.

These irregularities in the vertical Walls of the lobes and recesses enable the lobes to resist vertical dislodgeinent. The preferred male irregularity on the walls of the lobes 3 and the recesses between them is a bead 26 which winds continuously across the end wall E of the mat, into and out of each recess 23 and around the edge of each lobe 3. The preferred female irregularity on the vertical walls of the lobes 2 and recesses 23 at the end of the mat is a groove 2l complementary to bead 2S. When lobes 2 are meshed with lobes 3 this bead 2E fits into the groove 2l and makes vertical separation of the two ends of the respective mats very dicult.

To prevent the mats from being separated when they are twisted or flexed at the interlocked edges, the lobes E (Figs. l, 3 and l0) which are at the ends of the series of lobes 2, just inside the beveled edges il, and their corresponding recesses 23' on end (5 in which the lobes 2' are engaged are advantageously designed so that each lobe 2 may be fastened in its recess 23' by a screw fastener 28 (Figs. lO-and 11).

These lobes 2 are about half as thick as the lobes 2. The upper surface 2S of each lobe 2 is flush with the top surface of the adjacent mat material 8, and through each there is a hole 30 (Fig. 3) in which the upper half of fastener 28 is located. The recesses 23' which receive these thin lobes are each formed with a web 3l so that they are shallower than the other recesses. In the `web is a hole 32 (Fig. 3) in which the lower half of the fastener 23 is located.

When the lobes 2 are engaged with their respective recesses 23 each lobe 2 rests on the web of its recess, with hole 3d in register with hole 32. Fastener 23 is in two pieces (Fig. 1l). The lower piece is a threaded sleeve 33 which is inserted through hole 32 from the bottom of the web 3l. This lower piece of the sleeve is provided with a wide head Sil which bears against the bottom of the web 3l. The upper piece of the fastener is a flat-headed screw 35 which is inserted through the hole 3d and threaded into the sleeve 35. rEhe top surface of lobe 2 is preferably countersunk to receive the head of screw 35 when the two parts of the fastener are screwed tightly together.

If the mats are wide, e. g., six to eight feet, it will be desirable to forni thin lobes and webbecl 'ecesses at intervals among the thicker lobes as well as at each end of the set so that the center portions of the mats also may be fastened sesurelylhin lobes and webbed recesses may be lorrned wherever it is advantageous. Their purpose is to prevent any series of lobes and recesses from being unintentionally dislodged.

rEhe auxiliary fastener Z8 and the thin lobes may be omitted in heavier mats formed of firm plastic and also in mats which will not be subjected to frequent twisting or flexing of their interloclzed edges. In these mats the shape of the lobes and recesses together with the male and female irregularities is sufficient to keep the lobes and recesses interlocled.

There is a hole i2 (Figs. 5 and 8) countersunk in the under surface of each lobe. This hole per- 1 j. mits the sides of cach lobe to yield slightly when the mats are assembled and disassembled and gives added cushioning.

If it is desirable to turn the floor covering around an obstruction or corner, sector-shaped mats l (Fig. 2) are assembled with the rect-angular The radial edges le of each sector are provided with lobes i? and 3, respectively. Lobes 2 are formed at the ends of the series of lobes 2 on each mat and proper recesses 23 are provided for them at the ends of the series of lobes 3. The curved sides and the body 5i of these mats are of the saine crosssectional designs as the rectangular mats i. The radial edges 49 along which the lobes and recesses are located are about thirty degrees apart. Mats of this angularity are preferred for production purposes because they will be inost commonly used for making turns, although mats may be formed in sectors of ninety degrees or in any size necessary to obtain a desired pattern.

Mat 25 where the two runners intersect is square with lobes 2 on two sides and lobes 3 on the other two sides.

Finishing mat 2li used at the end of the floor covering shown in Fig. l is beveled along three sides 55 at the same angle as the sides 9 of the mats l. The lobes 2 of this mat mesh with the lobes 3 at the end t of mat l. Other finishing mats will be formed with lobes 3 adapted to mesh 5 with the lobes 2 at the ends 5 of mats, although none of these is shown.

This floor covering has many advantages over the conventional continuous strip plastic floor'- ing. The mats lie iiat and their sides need not be fastened to the iioor. The shipping of bulky materials is prevented because each oor covering is assembled at the site of its installation. This can be easily and quickly done and expert labor is not required. AShould a particular mat in any assembled length of ooring become excessively worn o1' soiled (as with paint, etc.) this mat may easily be replaced.

The invention is not limited to mats with lobes of the particular shape disclosed although molds of this contour are conveniently machined. The interlocking members need not be rounded. It is not necessary that the mats be molded. They may contain fibrous material and may be stamped or pressed to shape, although it would probably be impossible by such methods of manufacture to form interlocking male and female congurations in the vertical Walls of the mats. The mats may be a composite structure, e. g., the body portion may be of one material and. the lobed porto releasably interlock with recesses and lobes along the edge of another mat, the under surface of each lobe being individually countersunk to add resiliency to the mat, the interlocked area having at top and bottom surfaces and the ad jacent area being corrugated whereby lthe countersunk interlocked area has a resiliency at least approaching that of the corrugated area.

2. Floor covering composed of a plurality of the mats of claim 1, with the lobes and recesses on adjacent edges of the respective mats interlocked, at least one of the lobes on each edge of each mat being thinner than the adjacent mat material, a web across the corresponding recess, and fastening means joining said lobe and said web.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 348,782 Sawyer Sept. 7, 1886 1,019,212 Yates Mar. 5, 1912 1,288,409 Hayden Dec. 17, 1918 1,756,380 Osborn Apr. 29, 1930 2,048,544 Fritts July 21, 1936 FOREIGN PATENTS Number Country Date 319,416 Great Britain of 1929 349,130 Great Britain May 22. 1931 

1. A PLASTIC FLOOR MAT HAVING A PLURALITY OF LOBES SPACED BY RECESSES ALONG ONE EDGE ADAPTED TO RELEASABLY INTERLOCK WITH RECESSES AND LOBES ALONG THE EDGE OF ANOTHER MAT, THE UNDER SURFACE OF EACH LOBE BEING INDIVIUDALLY COUNTERSUNK TO ADD RESILIENCY TO THE MAT, THE INTERLOCKED AREA 